University of Pennsylvania ScholarlyCommons Department of Chemical & Biomolecular Senior Design Reports (CBE) Engineering 4-2016 Production of Propylene Oxide from Propylene Using Patented Silver Based Catalyst Eric W. Schultz University of Pennsylvania, [email protected] Mitchell B. Schwartz University of Pennsylvania, [email protected] Kyle M. Yu University of Pennsylvania, [email protected] Follow this and additional works at: https://repository.upenn.edu/cbe_sdr Part of the Biochemical and Biomolecular Engineering Commons Schultz, Eric W.; Schwartz, Mitchell B.; and Yu, Kyle M., "Production of Propylene Oxide from Propylene Using Patented Silver Based Catalyst" (2016). Senior Design Reports (CBE). 86. https://repository.upenn.edu/cbe_sdr/86 This paper is posted at ScholarlyCommons. https://repository.upenn.edu/cbe_sdr/86 For more information, please contact [email protected]. Production of Propylene Oxide from Propylene Using Patented Silver Based Catalyst Abstract Propylene oxide (PO) is an important intermediate in the manufacture of propylene glycol (PG), polyether polyols and many other products. Conventional production of propylene oxide has many drawbacks. The most common method, the chlorohydrin process produces chlorinated by products which must be disposed of. Other processes produce a co-product, like styrene, which adversely affects production economics. A team of scientists at the Council of Scientific and Industrial Research (CSIR) in New Delhi has recently applied for a patent for a catalyst that oxidizes propylene to PO in high yield. The primary motivation behind this project was the production of PO without the unwanted side products of traditional methods by using the direct oxidation in CSIR’s patent. Our proposed plant design produces 200 million lb/year of propylene oxide from propylene and will be located on the U.S. Gulf Coast. Our plant is divided into four sections, namely feed material pretreatment, direct oxidation reaction, initial separation, and final distillation. The byproducts include CO2, Acetal, Acrylic Acid, and Acrolein. CO2 is separated through adsorption-desorption cycle with monoethanolamine (MEA), other byproducts are separated by distillation, and PO product is 99.9822% pure by mass. The cost of purchase of propylene is $1,100/tonne and the selling cost of PO is $2500/tonne. The process has an estimated IRR of 81.91% and an NPV of $262,808,900.This report provides a detailed design and economic analysis for PO production in the Gulf Coast. Process flow sheets, energy and utility requirements and reactor design have been considered during our analysis below. The total cost of equipment is $35,715,726. Except for the most extreme variations of the price of PO, variable costs, fixed costs, and total permanent investment, the IRR remains strongly positive indicating the high chance of this project’s success even if factors outside of the group’s control negatively affect its economics. Due to its low risk and high reward, a license for the catalyst described in the patent should be acquired, and this process should be developed. Disciplines Biochemical and Biomolecular Engineering | Chemical Engineering | Engineering This working paper is available at ScholarlyCommons: https://repository.upenn.edu/cbe_sdr/86 4-12-2016 Production of Propylene Oxide from Propylene Using Patented Silver Based Catalyst Eric Schultz University of Pennsylvania Kyle Yu University of Pennsylvania Mitchell Schwartz University of Pennsylvania 1 Production of Propylene Oxide from Propylene Abstract Propylene oxide (PO) is an important intermediate in the manufacture of propylene glycol (PG), polyether polyols and many other products. Conventional production of propylene oxide has many drawbacks. The most common method, the chlorohydrin process produces chlorinated by products which must be disposed of. Other processes produce a co-product, like styrene, which adversely affects production economics. A team of scientists at the Council of Scientific and Industrial Research (CSIR) in New Delhi has recently applied for a patent for a catalyst that oxidizes propylene to PO in high yield. The primary motivation behind this project was the production of PO without the unwanted side products of traditional methods by using the direct oxidation in CSIR’s patent. Our proposed plant design produces 200 million lb/year of propylene oxide from propylene and will be located on the U.S. Gulf Coast. Our plant is divided into four sections, namely feed material pretreatment, direct oxidation reaction, initial separation, and final distillation. The byproducts include CO2, Acetal, Acrylic Acid, and Acrolein. CO2 is separated through adsorption-desorption cycle with monoethanolamine (MEA), other byproducts are separated by distillation, and PO product is 99.9822% pure by mass. The cost of purchase of propylene is $1,100/tonne and the selling cost of PO is $2500/tonne. The process has an estimated IRR of 81.91% and an NPV of $262,808,900.This report provides a detailed design and economic analysis for PO production in the Gulf Coast. Process flow sheets, energy and utility requirements and reactor design have been considered during our analysis below. The total cost of equipment is $35,715,726. Except for the most extreme variations of the price of PO, variable costs, fixed costs, and total permanent investment, the IRR remains strongly positive indicating the high chance of this project’s success even if factors outside of the group’s control negatively affect its economics. Due to its low risk and high reward, a license for the catalyst described in the patent should be acquired, and this process should be developed. Disciplines Biochemical and Biomolecular Engineering | Chemical Engineering | Engineering 2 University of Pennsylvania Department of Chemical and Biomolecular Engineering 220 South 33rd Street Philadelphia, PA 19104 April 5, 2016 Dear Dr. Seider and Professor Fabiano, Enclosed you will find the solution to the design problem presented by Bruce M. Vrana, DuPont. The proposed process design is for the industrial production of propylene oxide from propylene. The oxidation catalyst, silver oxide (Ag2O) supported on tungsten trioxide oxide (WO3), oxidizes propylene to PO in high yeild. The product is purified through adsorption-desorption cycle with monoethanolamine (MEA), and other byproducts are separated by distillation. The PO product is 99.9822% pure by mass and fits the purity specifications of industry leaders. The reactor effluent is fed through an adsorption- desorption cycle to remove the CO2. The product from the cycle is then taken through two distillation towers which remove any unwanted side products. The proposed plant will be located on the U.S. Gulf Coast and has the capacity to produce 200MM lb/year of propylene oxide. This report contains detailed process design, economic analysis, and conclusions and recommendations for the implementation of the plant. The proposed plant is found to be economically feasible. Except for the most extreme variations of the price of PO, variable costs, fixed costs, and total permanent investment, the IRR remains strongly positive indicating the high chance of this project’s success even if factors outside of the group’s control negatively affect its economics. It has an estimated IRR of 81.91% with a total NPV of $ 262,808,900. Most of the continuous operations in this process were modeled using Aspen Plus v8.6. Cost estimates for the equipment were obtained using the equations contained in Process Design Principles, 3rd Edition, by Seider, Seader, Lewin and Widagdo. Thank you for the assistance afforded to us during this project. Sincerely, ______________________________ Eric Schultz ______________________________ Mitchell Schwartz ______________________________ Kyle Yu 3 Eric Schultz | Mitchell Schwartz | Kyle Yu Production of Propylene Oxide from Propylene Senior Design Project, CBE 459 Project submitted to: Dr. Warren Seider Prof. Leonard Fabiano Dr. Robert Riggleman Project proposed by: Bruce M. Vrana, DuPont Dept. of Chemical and Biomolecular Engineering School of Engineering and Applied Science University of Pennsylvania April 5, 2016 4 Table of Contents 1.0 ABSTRACT ........................................................................................................................................... 8 2.0 INTRODUCTION ................................................................................................................................. 9 2.1 OBJECTIVE TIME CHART ............................................................................................................ 11 3.0 TECHNOLOGY READINESS ASSESSMENT .............................................................................. 12 3.1 INNOVATION MAP ........................................................................................................................ 12 3.2 BRIEF HISTORIES OF PREVIOUS TECHNOLOGIES ................................................................ 13 3.3 PATENT DETAILS AND TECHNOLOGY IMPLEMENTATION ............................................... 14 3.3.1 CATALYST TECHNICAL BACKGROUND .......................................................................... 15 3.4 MARKET ANALYSIS ..................................................................................................................... 18 3.4.1 INDUSTRIAL USES OF PROPYLENE OXIDE ..................................................................... 18 3.4.2 SIDE PRODUCTS ....................................................................................................................